Treatment of hydrocarbons



- 1949- P. M. ARNOLD TREATMENT 0F HYDROCARBONS 2 SheetIs-Sheet 1 Filed March 3, 1942 'INVENTOR ARNOLD f7 PHILIP M.

Oct. 4, 1949. P. M. ARNOLD TREATHENT OF HYDROCARBONS '2 Sheet-s -Sheet 2 Filed larch 3, @942 Patented Oct. 4, 1949 TREATMENT OF HYDROCARBON S Philip M. Arnold, Bartlesville, 0kla., assignor to Phillips Petroleum Company, a corporation of Delaware Application March 3, 1942, Serial No. 433,190

7 Claims. 1

This invention relates to a process for removing ethylene from admixture with other low boiling gases. In one of its more specific aspects this invention relates to a process for separation of ethylene from admixture with such gases as hydrogen, methane and other hydrocarbons higher boiling than ethylene. An object of my invention is to devise a process for the separation of ethylene from admixture with methane. another object of my invention is to devise a process for separating ethylene from admixture with methane and hydrocarbons higher boiling than ethylene. Still another object of my invention is to devise a process for the separation of ethylene from admixture with hydrogen, methane and normally gaseous hydrocarbons higher boiling than ethylene. Yet another object of my invention is to provide a process for the separation of relatively low boiling hydrocarbon from admixture with one or more constituents in the gaseous state without the use carbon mixture in a manner to facilitate the extremely low temperatures necessary for the removal of hydrogen and methane from the mixture by fractionation. The invention also involves the employment of properties possessed by certain constituents of the efliuent in a thermal conversion or other conversion process for the manufacture of butadiene,-namely methane and ethylene, for effecting the efiicient separation of ethylene from the methane and hydrogen, the recovery of butadiene and return of the ethylene to the conversion process for further production of butadiene. Specifically a refinery or other feed containing quantities of ethylene, hydrogen, methane and other hydrocarbons is combined with the efliuent of the thermal conversion operation, recycle gases from the fractionation-separation stage of the process and the whole subjected to a series of compressive and cooling stages prior to introduction into an initial fractionating section. The mixture is partially liquefied and cooled by passage through the bottom of the initial fractionating section, where at the same time it furnishes the required heat for fractionation. it is further cooled to a low temperature before passing into the first fractionating section from which the bulk of the ethylene content is recovered. The bottom product removed from the first section is further processed for the recovery of ethylene which is, in a continuous process, liquefied, expanded adiabatically and passed in heat exchange relationship first with the overhead from the first fractionating section and then with the feed mixture to the first fractionating section to cool said mixture to a sufiflciently low temperature to obtain satisfactory operation of said first fractionating section.

For securing the desired separation, it is necessary to produce a reflux composed of ethylene and methane in the first section which is maintained at a suitable superatmospheric pressure. The degree of cooling necessary to obtain an ethylene-methane reflux in the first fractionating section is a function of the pressure but it has been found that excessive pressures interfere with the fractionation. The cooling effected by the expanded ethylene on the overhead from the first section condenses a portion of ethylene and methane passing into the second fractionating section which is likewise maintained under superatmospheric pressure. On this section a reflux comprising principally methane is obtained for the separation of the remaining ethylene from the overhead of the first section by expanding a. portion of the liquid condensate formed in and withdrawn from this second section and passingthe same in heat exchange relationship with the overhead in said second section. A further portion of the liquid condensate is returned to the first section as reflux therefor. It is a noteworthy feature of this invention that following expansion of a portion of the liquid condensate utilized for refluxing principally methane, a phase separation occurs into methane and nearly pure ethylene liquid which is combined with the liquid ethylene recovered from the bottom product of the first fractionating section and expanded to successively cool the first section overhead and the initial feed mixture. The gas phase is recycled to the initial compression and cooling step. A propane or other type liquid refrigerant from an outside source is split into two streams, one of which is expanded and titiiiied to liquefy gaseous ethylene separated by fractionation from the eiliuent from the first fractionating section. The other stream is expanded and utilized for precooling the initial feed mixture prior to exchanging heat with the expanded ethylene st'ream. The propane streams are then recombined and returned for compression and recycling. The expanded ethylene stream including the ethylene recovered from the aforementioned phase separation after passing in heat exchange relationship with the overhead from the first fractionating section and the feed mixture is used to condense the reflux for a further fractionating tower in which the butadiene containingfraction is separated from lighter material, principally ethane, and for cooling the feed stream to that tower. The ethylene is there- 3 after compressed and fed into the cracking furnace to yield butadiene-and other products:

. Figures-1 and 2'illustrate diagrammatically a flow diagram of apparatus which may be employed for carrying out the process of this invenzvtion.

Referring to Figures 1 and 2 astream of gas containing ethylene obtained. by suitable means such as the conversion of propane, ethane or other hydrocarbon is 'fedinto the system.

through a conduit I where itis 'combinedwith" gases from a conduit 2 produced in the ethylene conversion step, and with recycled gases from a conduit II: Thecomposite stream is then :fed inioconduit-i and passed through a compression system including separators 51, 54 and 51, compressors 52 and 55 andcoolers 53 and 58 wherein it-is-compressed to about 300 poundsper square inch. absolute and leaves.-thesystem deprived oftar, benzene and heavier material at a-temperature of about 80 F. The-streamis-then led through a heat exchange coil I05 in the base-of atflrst fractionating column orsection A; where lines I 3, l0 and i1 and expanded through valve 80. Moving passage thmurhithe heat -exchanger the partiallyvaporized ethylene is utilized for precooling the initial feed mixture for section A.

Inntractionatmg section B a part or the liquid phase is returnedthmugh a gas trap 6 as reflux Bythesemeans-substantialiyahptfithe it gives up heat to liquid in the column. The

loss of heat reduces the-temperature oithestream to about F. and partially. liqueflesit which necessitates the use of a tank 58 for-phase sepw ethylene istremoved from the methane and hydrogen which leaves the exchangenatla temperature about --160 F throughconduitflr -Ihe:poution ottheliquid condensaterronr sec.-

tion B. which is expanded through alve it passes aration and amp id-for'transfer or theliquid phase to the tubes of-aheat exchanger m.- The gaseous phase passes tothe heat exchanger through a conduit 3A and the combined stream cooled to a temperature of about F. by heat exchange with expanded liquid propanewhich is in= a closedpropane refrigeration cycle, only shown in part. After passage-through heat exchanger IOI the feed stream passes through heat exchanger I02 in whichit is-cooled. to 'I4 E. by expanded ethylene from line ll'which'is recovered fromthebottom product of column A. The

cooled: composite feed stream-is-then passed into a-iirst fractionating column or sectionli.-

Fractionating column A is superimposedcby a second and smaller column or section B. The greater part of the ethylene is removedfromthe stream to section A as overhead material. This section A is refluxed by a stream composed primcipally of ethylene and flowing down fromwfractionator B through a trap 6. The low tempera ture of the feed stream obtained by. ethyleneexpansion facilitates the relatively low pressure, 300 pounds per square inch absolute, whichis desirable for proper fractionation. The upper portion of section A which is at a temperature of about 87 F. condenses the greater ai-tiof the ethylene and heavier compounds and-prevents them from passing with the overhead product in conduit 5 to the second fractlonating section B. The lower portion of section A has a temperature of about -13 F. and removes methane and hydrogen from the ethylene and heavier materials, so.that no appreciable quantity of these light materials leave the column kettle in conduit 4. The overhead product from section A consisting principally of methane, ethylene and hydrogen passes through a conduit 5 and a heat exchanger I04 in which it is cooled-to --130 F. partially condensing the gases and thereafter enters the through an.overheadvaporcondenser Hithence through the conduit-'- te. Br separatorrfli Asa reaultrof presqurereductionthrcughthe expann sionrvalvetl to 20-pounds persquaresinchanearly pure liquid ethyleneis sepmatedirom-methane and ethylene. vapor-in. separator 62- and pumped through conduitl I-tobecombined withpurifiod liquid: ethylene separated iromzthebottoms-oi fraotionating section A in a mannerto ba do-j scribed hereinafter; The bottom-product otsec-l time A. at. approximately -+I3 F. is pumped throughconduitl to the middle- 01 a iractionate ing column 0 which-is-for thepurpose 01'- separate ing substantially pure ethylenefrom ethane and heavier products. The-ethylene leavesthe top or column (1 at about .27 F. and through a back pressure regulator-valve 63 adapted tomaintain a-pressure otabout 300 pounds per square-inch in the=column.= The gaseous ethyleneatl-2T F. is condensed toliquidethyleneat about thesame temperatur (.-27 F. isapproximately the boiling point of ethylene under300' poundspressure) second fractionating section B in which a phase separation takes place. Fractionating section B is likewise maintained under a pressure of about 300 pounds per square inch. The extremelylow temperature in heat exchanger I is derived from expanded ethylene which with other hydrocarbons is withdrawn from section A through line .4, purified in fractionator 0, passed through inc. heat exchange vessel Hi9 by liquidpropane from. the aforementioned. closed refrigeration cycle and passes to accumulator 64 from which it is drawnthrough conduit It at '300ipounds per squareinchand at--27 F. Reflux for-column C. is .obtained by liquid ethylene pumped from accumulator 64 through line. ll. Liquid ethylene passesthrough-conduit I'Gand heat exchanger in! where it is cooled to --42 F. byheat exchange with overhead gases from section B composed of methane andhydrogen passing through conduit 8.. It is then combined with the ethylene in line l2.from.the phaseseparator 62. which collects expanded condensate from. section B, and -passes in-conduit. "through. valve Sliwhere it is ex-l pendedv into heat, exchanger. I04 at a. pressure approaching atmospheric as above described.

. Thebottom oticolumn C is maintained-at about F. .by ahot water orsteam coil I ill for the separation of ethylene from the ethane and heavier-which are withdrawn in line l5, cooled tor-25 F. in heat exchanger I I3, and passed into column Dinwhich a separation of ethane. from the heavier material including butadiene is obtained. Thebottom of column D is maintained at about 107 F. by a hot water'or steam coil Ill and ethane at F. is withdrawn as overhead product from the top of the column in line I8. The bottom product is withdrawn at 107 F. through line I9 and cooled to 52 F. by heat exchanger Ill, to 28 F. in heat exchanger H5 and 2 13. in heat exchanger I10, thereupon being passed from the system through line I 9 to a plant not shown for the separation of butadiene from heavier compounds.

The ethane in line I8 after its refrigeration capacity has been utilized in exchanger H5 for cooling the butadiene containing stream, is recycled through line I8 to the ethylene producing unit, not shown, or otherwise disposed of. The refrigerating capacity for heat exchanger H6 is obtained from gases comprising mainly methane which leave phase separator 62 at l60 F., pass through heat exchanger H6 and return through conduit II at 7 F. to be combined with thermal conversion eflluent and initial ethylene feed to the compression system in Figure 1.

The liquid ethylene product from conduit I'I expands isenthalpically through valve 60 into the shell of heat exchanger I04. The expanded ethylene is passed from exchanger I04 at -l50 F. into heat exchanger I02 to precool the initial feed mixture to section A thereby acquiring a temperature of 85 F. Thereafter, it is successively passed through line H into heat exchanger II2 to reflux a portion of the overhead product in column D, heat exchangers H3 at -45 F. and H4 at 32 to respectively precool the feed to column D and cool the butadiene stream for separation.

After its refrigerating capacity is thus fully utilized, the ethylene stream leaves heat exchanger II4 at 48 F. in line I! and passes through scrubber 65, compressor 65, Figure 1, and into the two coil thermal conversion unit 81. The efliuent from the conversion furnace leaves through conduits 2, 2 passes through tar separa' tors 68', B8 and is cooled in atmospheric heat exchanger 69. The efiuent is then treated for carbon or coke removal in a separator in which oil is passed countercurrent with the gases over a series of bailles in a tank 10. Oil is removed in line H and passed into settling tank 12 for separation of the suspended carbon or coke. Clear oil from the unit I2 is pumped back to tank I0 through line I4. Residual material is removed from the tank I2 through line I5. The purified gaseous effluent is passed through cooler 16 and combined with ethylene containing feed from line I and recycle material in line II for feed to the compression system and fractionating process as heretofore described.

The closed propane refrigeration'cycle so far as it is concerned with the present fractionating 6 heat exchanger l 06, and thence at 75 F. to control valve 203 through which it is expanded into heat exchanger IDI wherein it vaporizes in heat exchange with the initial feed stream 3 to the fractionating section A. The propane leaves exchanger IOI at 44 F. and passes to heat exchange tank I09. The second stream of propane liquid passes in conduit 202 at 80 F. through liquid control valve 204 and heat exchanger I08 to heat exchange-tank I09 at 6 F. In tank I09 the liquid propane from line 202 comes in contact with gaseous propane at -44 F. from line MI and itself vaporizes, the combined vapor passing upwardly through exchanger I08 and leaving the system through line 205 for recompression. The vapors in heat exchange tank I09 liquefy ethylene gases from column C as heretofore described.

The overhead product in line 8 from fractionating section B comprising methane and hydrogen at 160 F. has its refrigerating capacity utilized by passage through heat exchanger I01, becoming heated to 4'7 F. in precooling ethylene stream IE to the expansion valve 60, and thereafter by passing through exchanger I06 to cool propane stream in conduit 20I. The methanehydrogen mixture then leaves the system at 60 F. through line 8 for any desired utilization.

Summary of operation A gaseous feed stock containing ethylene and other gaseous hydrocarbons is combined with a recycle gaseous stream from a conversion furnace containing butadiene, ethylene and other gaseous hydrocarbons and the combined feed compressed to about 300 pounds per square inch absolute pressure. This compressed feed is then cooled and chilled to about 'l4 F. fractionated and the overhead product condensed and fractionated. again to produce a bottom product of relatively pure liquid ethylene. Some of this liquid is vaporized and the vapors expanded in heat exchange relation with the overhead product of the second fractionation step to produce reflux for this same fractionation step. The expanded vapors pass to the thermal conversion step while the ethylene remaining as liquid is expanded isentropically for utilization in the refrigeration of feeds to the second fractionato'r and to the first fractionator. This latter gaseous ethylene is combined with the other ethylene stream for passage to the conversion furnace in which some butadiene along with other hydrocarbons is siformed. These higher boiling hydrocarbons are process operates as follows: liquid propane entering line 200 from a compression system, not shown, is split into two streams in conduits 2M and 202. Stream 20I passes at 80 F. through fractionated from bottom of the first mentioned fractionation step.

The following Table I illustrates characteristics of the various streams and relative yields of materials based on a 24 hour run. All compositions and mol quantities are given on a pound mol basis.

Table I 1 2 3 4 5 6 7 8 9 10 ll 12 13 14 l5 l6 l7 i8 19 Mel: Mole Tots1/Day 3,8% 6,831 11,114 8,845 3,119 850 1,829 1,479 350 790 474 316 16,656 8,900 2,089 6,756 7,072[ 1.222 867 The following tableindlcates the heat transfer per dayiinlet-andexit=mol per cent vapor at eachheatexchangerinithe'fractionating systems has;

He as No. Vapor 13.x. u./Day

(ffffiiiit: 251 12 It is obvious that various changes maybe made in the apparatus'hereirr-shiown and' described without departing from the present'invention; The separation process may be-employed'for isolating acetylene, which presents a similar problem of separation trom= hydrogen and methane as ethylene; as well as other low boiling hydrocarbons by utilizing the principles or this invention.

I claim:

l. The process'for separating-ethylene from a mixture containing ethylene and methane and heavier hydrocarbons which comprises passing said mixture to a first'tractionating zone maintained under super-atmospheric pressureand at a temperature below the critical temperature of the mixture; withdrawing an overhead stream comprising methane and ethylene from said zone and passing said overhead stream to a second fractionating' zone maintained: under ,superatmospheric pressureand therein separating said overhead stream into a liquid condensate comprising mainly methane and ethylene and a gaseous overhead; refluxing said first zone with a portion of said liquid condensate and withdrawing the remaining portion of said liquid condensate from said second fractionating zone; 'expandingtsaidr remaining portion of condensate and passing the 8 same: intonindirecti heat exchange.- relationship; witlr overheadfrom-said second fractionating zone and; thereby; condensing 'fromsaid last named overhead'liquiidamethane as reflux for said second zone; refluxing-said secondzone with said liquid methane: withdrawing: abottomstreamcomprising ethylene. and .heavier hydrocarbons from thefirst rractionatingzone-and passingsaid stream to a third fractionating zonee separating ethylene from-said-rstreamlin said. thirdlfractionating zone and: removing; said separated ethylene from said' third zone and condensing same andsubsequently expanding said. condensed ethyleneandpassing the samein indirect heat exchange relation -.theoverhead stream from said-first fractionathmzone and thereby cooling saidroverheadfromsaid first fractionating prior to its introduction tosairl second fractionating zone;

2. The process-oilseparating-a re1atively.lowboiling hydrocarbon. from one or more constitue ents in a gaseous-mixture. which comprisespassing -said mixture to a first. fractionating, zone maintained under :superatmosphmdopressureand ata temperature below thecriticaltemperatune ofsaid mixture; supplying. liquid refluxncomprising said hydrocarbon and. a lower-boiling com stituent-of said mixtur tosaid first zone; passing overhead from-said first zone, comprising said hydrocarbon and a lowereboiling-constituent. to asecond iractionating zone maintained under superatmospheric pressure-andthereiniractionating said overheadintoaliduid condensate con.- sisting. essentially .of saidhydrocarbonnnd said lower-boiling constituent and'a gaseous overhead; expanding, a. portion-oi.said liquidycondensate. from. the second fractionating. zone and passing same-in indirect heatexchange relationship withithe -overheadhfromsaid second fractionating zone and. thereby. condensing. from said. overheada .liqnid. reflux. comprising ,said lower boiling-constituent; refliixing, saidlsecond zone with said..last-.named, li'quidreflumwithdrawing an .overhead'.fraction comprising substantially said. lower. boiling constituent from the.top.of.said' second fractionating zone; eme ploying the balance of said liquid condensate as said first-named. liquid reflux; and withdrawing abottom stream comprising said hydrocarbon from said first fractionating zone.

3, The processor. recovering ethylene in concentrated term from. a feedistream containing the same, together with methane which comprises introducing said feed stream into a first fractionating section-.at an intermediate point therein, removing from saidfirst section a bot? toms fraction containing ,the major part of the ethylene contained in the feed and an overhead fraction containing methane and. ethylene, cool-.- ingsaid overhead fraction. and introducing same toa second and separate fractionatingsection. separating-in said second section a. gas phase as an overhead and as a bottoms product a. liquid condensate composed principally of ethylene and methane, refluxing the top of said first section with a portion of said condensate, expanding the balance of said condensate and passing same in indirect heat exchange with said gas phase and thereby condensing therefrom a liquid stream composed principally of methane and thereby removing substantially all of the ethylene from said gas phase, refluxing said second section with said liquid stream composed principally of methane, withdrawing the uncondensed portion of'saidgas phase, said uncondensed portion comprising principally methane, and recovering 2,4ss,eee

"nearly pure ethylene from said bottoms product as the product of the process.

4. The process of recovering ethylene in concentrated form from a feed stream cotaining the same together with methane and hydrocarbons heavier than ethylene which comprises introducing said feed stream into a first fractionating section at an intermediate point therein, removing from said first section a bottoms fraction containing said hydrocarbons heavier than ethylene and the major part of the ethylene contained in the feed and an overhead fraction containin methane and ethylene, cooling said overhead fraction and introducing same to a second and separate fractionating section, separating in said second section a gas phase as an overhead and as a bottoms product a liquid condensate composed principally of ethylene and methane, refluxing the top of said first section with a portion of said condensate, expanding the balance of said condensate and passing same in indirect heat exchange with said gas phase and condensing therefrom a liquid stream composed principally of methane, refluxing said second section with said liquid stream composed principally of methane for removal of substantially all of the ethylene from said gas phase, withdrawing the uncondensed portion of said gas phase, said uncondensed portion comprising substantially methane and fractionating said bottoms fraction in a third and separate fractionating section to recover overhead nearly pure ethylene and a bottoms product comprising said heavier hydrocarbons.

5. The process of claim 4 wherein products produced by said expansion step are separated into a liquid phase of nearly pure ethylene and a gaseous phase containing methane, and said liquid phase is expanded and passed in indirect heat exchange with said overhead from said first section to cool the same to the proper tempera ture prior to introduction to said second section, and removing the expanded ethylene.

6. The process of claim 4 wherein products produced by said expansion step are separated into a liquid phase of nearly pure ethylene and a gaseous phase containing methane, ethylene recovered as overhead from said third section is condensed to give a second liquid phase of nearly pure ethylene, and said liquid phases of nearly pure ethylene are combined, expanded and passed in indirect heat exchange with said overhead from said first section to cool the same to the proper temperature prior to introduction to said second section, and removing the latter expanded ethylene as a product of the process.

'7. The process of recovering ethylene in concentrated form from a feed stream containing hydrogen, methane, ethylene and heavier hydrocarbons which comprises passing said feed stream in heat exchange with expanded nearly pure ethylene prepared as hereinafter described and thereby cooling said feed stream to about 74 F., introducingthe resulting cooled feed stream at about '74 F. into a first fractionating section at an intermediate point therein, operating said first section at a pressure of about 300 pounds per square inch absolute with a top temperature of about -87 F. and a bottom temperature of about -13 F., supplying to the top said first section a liquid reflux comprised principally of ethylene and methane in approximately equimolecular proportions and prepared as hereinafter described, removing from said first section a bottoms fraction containing the major part of the ethylene contained in the feed together with substantially all of the heavier hydrocarbons contained in the feed, removing from said first section an overhead consisting principally of methane, ethylene and hydrogen, passing said overhead in heat exchange with said expanded ethylene before it passes to said first heat exchanging step and thereby cooling said overhead to about --l30 F. and partially condensing the gases therein, introducing the resulting cooled material at about 130 F. into a second fractionating section, operating said second section at a pressure of about 300 pounds per square inch absolute with a top temperature of about -240 F., separating in said second section a gas phase as an overhead and as a bottoms' product a liquid condensate composed principally of ethylene and methane, employing a portion of said condensate as said reflux supplied to the top of said first section, withdrawing said gas phase from said second section, expanding the balance of said condensate in indirect heat exchange with said gas phase and thereby condensing from said gas phase a liquid stream composed principally of methane and thereby removing substantially all of the ethylene from said gas phase, refluxing said second section with the resulting liquid stream, withdrawing from the system the gaseous stream composed essentially of methane and hydrogen left as a residue of said gas phase from said expanding step, passing the expanded condensate to a separating zone maintained at low pressure and there separating nearly pure liquid ethylene from a gaseous phase containing methane, introducing the bottoms product from said first section to a third fractionating section operated at about 300 pounds per square inch absolute and with a top temperature of about 27 F. and a bottom temperature of about 80 F., withdrawing from said third section an overhead of nearly pure ethylene, condensing said overhead, supplying a part of the resulting liquid condensate to the top of said third section as reflux therefor, combining the remainder of said resulting liquid condensate with said nearly pure liquid ethylene mentioned above, and expanding the resulting nearly pure liquid ethylene and passing same first in indirect heat exchange with said first-named overhead and then in indirect heat exchange with said feed stream, and thereafter withdrawing the expanded ethylene from the system as the product.

PHILIP M. ARNOLD.

REFERENCES CITED UNITED STATES Pa'rmrrs Number Name Date 2,067,349 Schuftan Jan. 12, 1937 6 2,180,200 De Baufre Nov. 14, 1939 2,214,790 Greenewalt Sept. 17, 1940 2,240,925 De Baufre May 6, 1941 FOREIGN PATENTS Number Country Date 15,049 Great Britain 1913 17,235 Great Britain 1912 Certificate of Correction Patent No. 2,483,869 October 4, 1949 PHILIP M. ARNOLD Itis hereby certified that error appears in the printed specification of the above numbered patent requiririg correction as follows: e

Column 10, line 18, for 240 F. read 204 F.;

and that the said Letters Patent should be read with this correction therein that the e may conform to the record of the case inthe Patent Ofiioe. Signed and sealed this 28th day of February, A. D. 1950.

THOMAS F. MURPHY,

Assistant Oommjuianer of Patent. 

